U.S. patent application number 16/265267 was filed with the patent office on 2020-08-06 for card stacker.
The applicant listed for this patent is Assa Abloy AB. Invention is credited to Ted M. Hoffman, John Skoglund, Tanya Snyder.
Application Number | 20200247637 16/265267 |
Document ID | / |
Family ID | 1000003880003 |
Filed Date | 2020-08-06 |
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United States Patent
Application |
20200247637 |
Kind Code |
A1 |
Hoffman; Ted M. ; et
al. |
August 6, 2020 |
CARD STACKER
Abstract
A card stacker includes a stack support that supports a stack of
card substrates, a card lift mechanism, a card feed mechanism, and
a retraction mechanism. The card lift mechanism is configured to
support the card substrate in a lift position below the stack
support, and drive the card substrate to a raised position, in
which the card substrate is supported on the stack support at the
bottom of the stack. The card feed mechanism includes a first
transport roller having a feed position, in which the first
transport roller engages a top surface of the card substrate in the
lift position, and a retracted position when the card substrate is
in the raised position, in which the first transport roller is on
the bottom side of the stack support. The retraction mechanism is
configured to move the first transport roller between the feed and
retracted positions.
Inventors: |
Hoffman; Ted M.; (Eden
Prairie, MN) ; Snyder; Tanya; (Edina, MN) ;
Skoglund; John; (Prior Lake, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Assa Abloy AB |
Stockholm |
|
SE |
|
|
Family ID: |
1000003880003 |
Appl. No.: |
16/265267 |
Filed: |
February 1, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65H 5/06 20130101; B65H
2404/144 20130101; B65H 29/14 20130101; B65H 31/00 20130101; B65H
2701/1914 20130101; B65H 29/46 20130101; B65H 29/22 20130101 |
International
Class: |
B65H 29/46 20060101
B65H029/46; B65H 31/00 20060101 B65H031/00; B65H 29/14 20060101
B65H029/14; B65H 5/06 20060101 B65H005/06 |
Claims
1. A card stacker for use with a card production device and
configured to deliver a card substrate to a bottom of a stack of
card substrates, the card stacker comprising: a stack support
configured to hold the stack of card substrates on a top side of
the stack support that is opposite a bottom side of the stack
support; a card lift mechanism configured to support the card
substrate in a lift position on the bottom side of the stack
support, and drive the card substrate to a raised position, in
which the card substrate is positioned at the bottom of the stack
of card substrates and is supported by the top side of the stack
support; a card feed mechanism comprising a first transport roller
having a feed position when the card substrate is in the lift
position, and a retracted position when the card substrate is in
the raised position, wherein: the first transport roller engages a
top surface of the card substrate that faces the bottom side of the
stack support when in the feed position; and when in the retracted
position, the first transport roller is displaced from a lifting
path of the card substrate defined between the lift and raised
positions; and a retraction mechanism configured to move the first
transport roller between the feed and retracted positions.
2. The card stacker of claim 1, wherein the card lift mechanism
includes: a card support member; and a drive mechanism configured
to drive the card support member between a lowered position
corresponding to the lift position of the card substrate and a
raised position corresponding to the raised position of the card
substrate.
3. The card stacker of claim 2, wherein the retraction mechanism
includes a first pivotable support attached to the card support
member and configured to pivot the first transport roller about a
first support axis to the retracted position in response to
movement of the card support member from the lowered position to
the raised position.
4. The card stacker of claim 3, wherein the card feed mechanism
includes a second transport roller, and the card substrate is
pinched between the first and second transport rollers when the
card substrate is in the lift position.
5. The card stacker of claim 4, wherein the pivotable support is
biased to pivot the first transport roller about the first support
axis toward the top surface of the card substrate when the card
substrate is in the lift position.
6. The card stacker of claim 5, wherein: the first and second
transport rollers form a first pinch roller pair configured to
pinch the card substrate in the lift position adjacent a first edge
of the card substrate; and the card feed mechanism includes a
second pinch roller pair comprising third and fourth transport
rollers, wherein the card substrate in the lift position is pinched
between the third and fourth transport rollers at a second edge of
the card substrate that is opposite the first edge.
7. The card stacker of claim 6, wherein: the third transport roller
includes a feed position when the card substrate is in the lift
position and a retracted position when the card substrate is in the
raised position; the third transport roller engages the top surface
of the card substrate when in the feed position; the third
transport roller is displaced from the lifting path of the card
substrate when in the retracted position; and the retraction
mechanism is configured to move the third transport roller between
the feed and retracted positions.
8. The card stacker of claim 7, wherein the retraction mechanism
includes a second pivotable support attached to the card support
member and configured to pivot the third transport roller about a
second support axis to the retracted position in response to
movement of the card support member from the lowered position to
the raised position.
9. The card stacker of claim 2, wherein the card support member
engages a bottom surface of the card substrate that is opposite the
top surface and drives the card substrate from the bottom side of
the stack support to the top side of the stack support during
movement of the card support member from the lowered position to
the raised position.
10. The card stacker of claim 9, wherein the stack support
comprises a plurality of catch pawls.
11. The card stacker of claim 9, wherein: the drive mechanism
includes a motor and a threaded rod that is received within a
threaded bore of the card support member; and the card support
member is driven from the lowered position to the raised position
in response to rotation of the threaded rod driven by the
motor.
12. The card stacker of claim 2, further comprising a first port,
through which the card feed mechanism is configured to receive or
discharge individual card substrates when the card support member
is in the lowered position.
13. The card stacker of claim 12, further comprising a second port,
through which the card feed mechanism is configured to receive or
discharge individual card substrates when the card support member
is in the lowered position, wherein the second port is on an
opposing side of the card lift mechanism from the first port.
14. The card stacker of claim 2, wherein: the card feed mechanism
is configured to feed card substrates along a card feed path; and
the card stacker includes a card sensor configured to detect a
presence or an absence of a card substrate in the card feed
path.
15. The card stacker of claim 14, further comprising: a stack
housing having a bottom end supporting the stack support; and a
stack sensor configured to sense a top card substrate in the stack
of card substrates that is opposite the bottom of the stack of card
substrates.
16. A card stacker assembly for use with a card production device
and configured to deliver a card substrate to a bottom of a stack
of card substrates, the card stacker assembly including a plurality
of card stackers each card stacker comprising: a stack support
having a top side configured to hold the stack of card substrates;
a card lift mechanism configured to drive a card substrate from a
lowered position on a bottom side of the stack support that is
opposite the top side to a raised position, in which the card
substrate is positioned at the bottom of the stack of card
substrates and is supported by the top side of the stack support;
and a card feed mechanism comprising first and second pinch roller
pairs respectively configured to receive or discharge individual
card substrates along a card path through first and second ports
positioned on opposing sides of the card lift mechanism; wherein:
the plurality of card stackers is positioned in a side-by-side
arrangement; and a card substrate discharged through the second
port of one of the card stackers is received through the first port
of an adjoining card stacker.
17. The card stacker assembly of claim 16, wherein: the first and
second pinch roller pairs each include a transport roller having a
feed position when the card substrate is in the lowered position
and a retracted position when the card substrate is in the raised
position; the transport roller engages a top surface of the card
substrate that faces the bottom side of the stack support when in
the feed position; when in the retracted position, the transport
roller is displaced from a lifting path of the card substrate
defined between the lowered and raised positions; and each card
stacker includes a retraction mechanism configured to move the
transport rollers of the first and second pinch roller pairs
between the feed and retracted positions.
18. The card stacker assembly of claim 17, wherein each of the
retraction mechanisms includes a pivotable support configured to
pivot the transport roller about a support axis to the retracted
position in response to driving, by the card lift mechanism, of the
card substrate from the lowered position to the raised
position.
19. A method of adding a card substrate to a bottom of a stack of
card substrates supported on a top side of a stack support of a
card stacker, the method comprising: receiving the card substrate
with a card feed mechanism of the card stacker, the card feed
mechanism including a transport roller; supporting the card
substrate in a lowered position on a bottom side of the stack
support including engaging a top surface of the card substrate that
faces the bottom side of the stack support with the transport
roller in a feed position; raising the card substrate from the
lowered position to a raised position, in which the card substrate
is positioned on the bottom of the stack of card substrates and
supported on the top side of the stack support, using a card lift
mechanism of the card stacker; and during raising the card
substrate, moving the transport roller from the feed position to a
retracted position, in which the transport roller is displaced from
a lifting path of the card substrate defined between the lowered
and raised positions.
20. The method of claim 19, further comprising performing a process
on the card substrate using a card processing device before
receiving the card substrate with the card feed mechanism, wherein
the process is selected from the group consisting of: printing an
image on the card substrate; laminating an overlaminate to the card
substrate; and encoding data to the card substrate.
Description
FIELD
[0001] Embodiments of the present disclosure relate to a card
stacker for stacking card substrates and, more specifically, to a
card stacker that is configured to deliver card substrates to the
bottom of a stack of card substrates.
BACKGROUND
[0002] Card products include, for example, credit cards,
identification cards, driver's licenses, passports, and other card
products. Such card products generally include printed information,
such as a photo, account numbers, identification numbers, and other
personal information. Credentials can also include data that is
encoded in a smartcard chip, a magnetic stripe, or a barcode, for
example.
[0003] Card production devices include processing devices that
process card substrates to form the final card product. Such
processes generally include a printing process, a laminating or
transfer process, a data reading process, a data writing process,
and/or other process used to form the desired credential.
Credential production devices typically include a collection unit,
such as a hopper or other container, for collecting the processed
card products.
SUMMARY
[0004] Embodiments of the present disclosure are directed to a card
stacker for use with a card production device, a card stacker
assembly that includes a plurality of the card stackers, and
methods of using the card stacker to add a card substrate to a
bottom of a stack of card substrates. One embodiment of the card
stacker is configured to deliver a card substrate to a bottom of a
stack of card substrates and includes a stack support, a card lift
mechanism, a card feed mechanism, and a retraction mechanism. The
stack support is configured to hold the stack of card substrates on
a top side of the stack support that is opposite a bottom side of
the stack support. The card lift mechanism is configured to support
the card substrate in a lowered position on the bottom side of the
stack support, and drive the card substrate to a raised position,
in which the card substrate is positioned at the bottom of the
stack of card substrates and is supported by the top side of the
stack support. The card feed mechanism includes a first transport
roller having a feed position when the card substrate is in the
lowered position, and a retracted position when the card substrate
is in the raised position. The first transport roller engages a top
surface of the card substrate that faces the bottom side of the
stack support when in the feed position. The first transport roller
is on the bottom side of the stack support when in the retracted
position. The retraction mechanism is configured to move the first
transport roller between the feed and retracted positions.
[0005] One embodiment of the card stacker assembly includes a
plurality of card stackers, each card stacker configured to deliver
a card substrate to a bottom of a stack of card substrates. Each of
the card stackers includes a stack support, a card lift mechanism,
and a card feed mechanism. The stack support includes a top side
configured to hold the stack of card substrates. The card lift
mechanism is configured to drive the card substrate from a lowered
position on a bottom side of the stack support that is opposite the
top side to a raised position, in which the card substrate is
positioned at the bottom of the stack of card substrates and is
supported by the top side of the stack support. The card feed
mechanism includes first and second pinch roller pairs that are
respectively configured to receive or discharge individual card
substrates along a card path through first and second ports
positioned on opposing sides of the card lift mechanism. The
plurality of card stackers are positioned in a side-by-side
arrangement. A card substrate discharged through the second port of
one of the card stackers is received through the first port of an
adjoining card stacker.
[0006] In one embodiment of a method of adding a card substrate to
a bottom of a stack of card substrates supported on a top side of a
stack support of a card stacker, the card substrate is received
with a card feed mechanism of the card stacker. The card feed
mechanism includes a transport roller. The card substrate is
supported in a lowered position on a bottom side of the stack
support, which includes engaging a top surface of the card
substrate that faces the bottom side of the stack support with the
transport roller in a feed position. The card substrate is raised
from the lowered position to a raised position, in which the card
substrate is positioned on the bottom of the stack of card
substrates and is supported on the top side of the stack support
using a card lift mechanism of the card stacker. The transport
roller is moved from the feed position to a retracted position, in
which the transport roller is positioned and on the bottom side of
the stack support during the raising of the card substrate.
[0007] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used as an aid in determining the scope of
the claimed subject matter. The claimed subject matter is not
limited to implementations that solve any or all disadvantages
noted in the Background.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a simplified illustration of a card production
system in accordance with embodiments of the present
disclosure.
[0009] FIG. 2 is a simplified side view of an exemplary card
stacker, in accordance with embodiments of the present
disclosure.
[0010] FIGS. 3 and 4 are isometric assembled and exploded views of
an exemplary card stacker, in accordance with embodiments of the
present disclosure.
[0011] FIGS. 5-9 are simplified side views of an exemplary card
stacker during various stages of the lift or stacking operation, in
accordance with embodiments of the present disclosure.
[0012] FIG. 10 is an isometric view of an exemplary base of a card
stacker, in accordance with embodiments of the present
disclosure.
[0013] FIGS. 11-14 are side cross-sectional views of the base of
FIG. 9 taken generally along line 10-10, during various stages of a
substrate lifting or stacking operation.
[0014] FIGS. 15 and 16 are simplified partial side views of a card
stacker 104 in accordance with embodiments of the present
disclosure.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0015] Embodiments of the present disclosure are directed to a card
stacker that may be used with a card production device to deliver
card substrates to a bottom of a stack of card substrates contained
in the card stacker. In some embodiments, the card stacker is a
modular device that may be combined with other card stackers to
increase the card stacking capacity of the card production
system.
[0016] These and other embodiments of the present disclosure are
described more fully hereinafter with reference to the accompanying
drawings. Elements that are identified using the same or similar
reference characters refer to the same or similar elements. The
various embodiments of the present disclosure may, however, be
embodied in many different forms and should not be construed as
limited to the embodiments set forth herein. Rather, these
embodiments are provided so that this disclosure will be thorough
and complete, and will fully convey the scope of the present
disclosure to those skilled in the art.
[0017] FIG. 1 is a simplified illustration of a card production
system 100 that includes a card production device 102 and one or
more card stackers 104 formed in accordance with embodiments of the
present disclosure. While the system 100 is shown as including a
card stacker assembly 106 formed of three card stackers 104A-C, it
is understood that embodiments of the present disclosure include
systems 100 that include a single card stacker 104, or a card
stacker assembly 106 comprising two or more card stackers 104.
[0018] The system 100 also includes a controller 108 and one or
more card processing devices 110. The controller 108 represents one
or more distinct controllers of the system 100 each including at
least one processor that is configured to execute program
instructions stored in a computer-readable media or memory of the
device 100, which may also be represented by the controller 108, or
another location. Any suitable patent subject matter eligible
computer readable media or memory may be utilized including, for
example, hard disks, CD-ROMs, optical storage devices, flash
memory, magnetic storage devices, or other suitable computer
readable media or memory. Such computer readable media or memory do
not include transitory waves or signals. The execution of the
instructions by the controller 108 controls components of the
system 100 to perform functions and method steps described
herein.
[0019] The one or more card processing devices 110 are each
configured to perform a process on a card substrate 112. The card
processing devices may include conventional card processing
devices, such as a printing device configured to print an image to
a surface of the card substrate 112 through a direct or transfer
printing process, a laminating device configured to apply an
overlaminate to a surface of the substrate 112, a data reading
and/or writing device (e.g., a chip encoder, a magnetic stripe
encoder, etc.) configured to read data from, and/or write data to,
the substrate 112, a card flipper configured to invert the
substrate 112, and/or another conventional card processing
device.
[0020] In some embodiments, individual substrates 112 may be
received at an input 114 by the card production device 110 from a
card substrate supply 116, as shown in FIG. 1, or another device of
the system 100. A transport mechanism 118 feeds individual
substrates 112 along a processing path 119 to the one or more
processing devices 110. The transport mechanism 118 may include
conventional motorized feed rollers and pinch roller pairs 120, as
shown in FIG. 1. The card stackers 104 may be positioned to receive
individual card substrates 112 discharged through an output 122 of
the card production device 102 by the transport mechanism 112, as
shown in FIG. 1.
[0021] Embodiments of the card stacker 104 will be described with
reference to the FIGS. 2-4. FIG. 2 is a simplified side view of an
exemplary card stacker 104, and FIGS. 3 and 4 are isometric
assembled and exploded views of an exemplary card stacker 104. As
discussed in greater detail below, each of the card stackers 104
includes a stack support 124, a card feed mechanism 126, and a card
lift mechanism 128, as shown in FIG. 2. The card feed mechanism 126
of each card stacker 104 is generally configured to feed individual
card substrates 112 along a card feed path 130, which may be
aligned with the processing path 119 (FIG. 1) of the card
production device 102, to a lift position 132 within the card
stacker 104 or to handoff the substrate to the next card stacker
104. Each lift mechanism 128 is configured to perform a lift
operation on individual substrates 112 that are positioned in the
lift position 132 within the card stacker 104. The lift operation,
which is illustrated as being performed by the card lift mechanism
128 of the card stacker 104C, delivers the substrate 112 from the
lift position 132 in the card feed path 130 to the bottom of a card
stack 136 of substrates 112S supported on the stack support
124.
[0022] In some embodiments, each card stacker 104 includes a stack
housing 140 that is removably supported within a receptacle 142 of
a base 144, which includes the card lift mechanism 128 and the card
feed mechanism 126. The stack housing 140 defines an interior
cavity 146 that is configured to contain the card stack 136, as
shown in FIG. 2. The housing 140 may include an access to the
interior cavity 146, such as a hinged door 148 (FIGS. 3 and 4) or
other suitable access, for removal of the card stack 136. The door
148 may be locked using a suitable locking mechanism 150.
[0023] The stack support 124 is supported at a bottom 152 of the
stack housing 140 adjacent an opening 154 in the housing 140, and
is configured to support the substrate stack 136 in a vertical
column within the interior cavity 146 that is generally aligned
with an axis 156. During a substrate lifting operation, a substrate
112 is delivered through the opening 154 in the bottom 152 of the
housing 140 adjacent the stack support 124 to the bottom of the
substrate stack 136 and on the stack support 124.
[0024] The stack support 124 may take on any suitable form. In one
example, the stack support 124 includes multiple catch pawls 158
that may be pivoted in the direction indicated by arrows 160 (FIG.
2) during a lift operation, but are restricted from pivoting in the
direction opposite the arrows 160 past a support position, which is
shown in FIG. 2. The stack support 124 may include, for example,
three or four catch pawls 158 that support the bottom surface 162
of the bottom substrate 112S of the stack 136 in a substantially
perpendicular orientation to the axis 156, as shown in FIG. 2.
[0025] Each card feed mechanism 126 is configured to receive
substrates 112 through a port 164, feed the individual substrates
112 along the card feed path 130 to the lift position 132, in which
the substrate 112 is positioned for a lifting operation using the
corresponding lift mechanism 128, or deliver the substrates to an
adjoining card stacker 104 through a port 166 on the opposing side
of the axis 156 from the port 164. For example, with reference to
FIG. 1, the card feed mechanism 126 of the card stacker 104A is
configured to receive individual card substrates 112 discharged
through the output 122 of the card production device 102 at the
port 164 and feed the substrate 112 along the card feed path 130 to
the lifting position 132, in which the lift mechanism 128 may
perform a lift operation, or discharge the substrate 112 through
the port 166 where it is received by the card feed mechanism 126 of
the card stacker 104B through the port 164. Likewise, the card feed
mechanism 126 of the card stacker 104B may feed the substrate 112
received from the card stacker 104A to position it for a lift
operation or handoff the substrate 112 to the card feed mechanism
126 of the card stacker 104C, such as indicated by the substrate
112 drawn in phantom lines. The card stacker 104C, which is the
last card stacker of the assembly 106 in the exemplary system 100
of FIG. 1, may use its card feed mechanism 126 to position the card
substrate 112 for a lift operation using its lift mechanism 128 to
deliver the substrate 112 to the bottom of the card stack 136
supported by the stack support 124, as indicated in FIG. 1, or
discharge the card substrate 112 through the port 166, for
example.
[0026] The card feed mechanism 126 of each card stacker 104 can
take on any suitable form. In some embodiments, the card feed
mechanism 126 includes pinch roller pairs 168, such as pinch roller
pairs 168A and 168B, which are respectively positioned on opposing
sides of the axis 156 adjacent the ports 164 and 166. Each of the
pinch roller pairs 168 include upper and lower transport rollers
170 and 172, respectively, such as upper transport rollers 170A and
170B, and lower transport rollers 172A and 172B. While the card
feed mechanism 126 is illustrated as having two pinch roller pairs
168A and 168B, embodiments of the present disclosure include the
use of the single pinch roller pair or other configurations.
[0027] The pinch roller pairs 168 are configured to drive a
received substrate 112 along the card feed path 130 when in a feed
position, such as shown in FIG. 2. When in the feed position, one
or both of the pinch roller pairs 168A and 168B pinch a received
substrate 112 between the upper and lower transport rollers 170 and
172 and support the substrate 112 in substantial alignment with the
card feed path 130.
[0028] A motor 174 is configured to drive the pinch roller pairs
168, such as through a conventional mechanical linkage, to feed a
received card substrate 112 along the card feed path 130. In some
embodiments, the motor 174 is configured to drive the lower
transport rollers 172, and the upper transport rollers 170 are
idler motors that are not directly driven by the motor 174.
[0029] In some embodiments, the card feed mechanism 126 includes a
card sensor 176 that is configured to detect reception of a card
substrate 112 fed along the card feed path 130, such as from the
card production device 102 or an adjoining card stacker 104, for
example. In some embodiments, the card sensor 176 is used to detect
a leading or trailing edge of the substrate 112 to establish a
position of the substrate 112 relative to the card feed mechanism
126 along the card feed path 130. This allows the controller 108 to
control the card feed mechanism 126 to position the substrate 112
in the lift position 132 along the card feed path 130, or handoff
the substrate 112 to an adjoining card stacker 104. In some
embodiments, the motor 174 is a stepper motor, and the detection of
the leading or trailing edge of the substrate 112 using the card
sensor 176 allows the controller 108 to position the substrate 112
in a desired location along the card feed path 130 relative to the
card feed mechanism 126 by driving the motor 174 a predetermined
number of steps.
[0030] As discussed above, the card feed mechanism 126 is
configured to position a received substrate 112 in a lift position
132 (FIG. 2) along the card feed path 130 for a lifting operation.
In some embodiments, the pinch roller pairs 168A and 168B
simultaneously support the substrate 112 when it is in the lift
position 132. Thus, in some embodiments, the upper transport
rollers 170 of the pinch roller pairs 168A and 168B each engage a
top surface 178 of the card substrate 112 when it is in the lift
position 132, and the bottom transport rollers 154 each engage a
bottom surface 179 of the substrate 112 when it is in the lift
position 132.
[0031] Some embodiments of the lift mechanism 126 include a card
support member 180 and a drive mechanism 182, which is driven by a
motor 183 (FIG. 2), such as through a conventional mechanical
linkage. The card support member 180 has a lowered position, shown
in FIG. 2, that corresponds to the feed position of the pinch
roller pairs 168A and 168B and the lift or lowered position 132 of
the card substrate 112, in which the substrate 112 is aligned with
the card feed path 130, as shown in FIG. 2. In some embodiments,
the card support member 180 includes a top surface 184 that can
support the substrate 112 as it is fed along the card feed path
130. For example, when a card substrate 112 is received by the
pinch roller pair 168A, the leading edge of the substrate 112 may
be supported by the top surface 184 of the card support member 180
as the leading edge of the card substrate 112 as it is fed to the
pinch roller pair 168B.
[0032] During a lift operation, the lift mechanism 128 delivers a
card substrate 112 supported on the card support member 180 from
the lift position 132 (FIG. 2) along the axis 156 through the
opening 154 of the stack housing 140 to the bottom of the card
stack 136 using the drive mechanism 182, as generally illustrated
by the card stacker 104C in FIG. 1. The drive mechanism 182 may
take on any suitable form. In some embodiments, the drive mechanism
182 includes a threaded rod 186 that is received within a threaded
bore 188 of the card support member 180, as indicated in FIG. 2.
The rod 186 may be substantially coaxial to the axis 156. The motor
183 drives rotation of the rod 186 about the axis 156, and the
threaded engagement with the card support member 180 drives the
card support member 180 along the axis 156 either toward or away
from the card stack 136.
[0033] When the card substrate 112 is in the lift position 132
within a card stacker 104, one or more components of the card feed
mechanism 126 block the desired lifting path of the substrate 112
to the bottom of the card stack 136. For example, when the
substrate 112 is supported between the pinch roller pairs 168A and
168B, and the upper transport rollers 170 engage the top surface
178 of the substrate 112. As a result, the position of the upper
transport rollers 170 between the substrate 112 and the opening 154
to the housing 140 prevent the delivery of the substrate 112 to the
bottom of the card stack 136.
[0034] In some embodiments, each card stacker 104 includes a
retraction mechanism, which is generally indicated by box 190 in
FIG. 2. The retraction mechanism 190 is configured to facilitate a
lift or stacking operation by clearing the one or more components
of the card feed mechanism 126 from the desired lifting path for
substrate 112, which allows the lift mechanism 128 to deliver the
substrate 112 to the bottom of the card stack 136 supported on the
stack support 124. In some embodiments, the retraction mechanism
190 is configured to move the upper transport rollers 170A and 170B
of the pinch roller pairs 168A and 168B from the lifting path of
the card substrate 112 to facilitate a lifting operation.
[0035] Exemplary embodiments of the retraction mechanism 190 will
be described along with an exemplary lift or stacking operation
with reference to FIGS. 2 and 5-9, which are each simplified side
views of an exemplary card stacker 104 during various stages of the
lift or stacking operation. Initially, with the pinch roller pairs
168A and 168B in the feed position and the lift mechanism 128 in
its lowered position, the substrate 112 is fed along the card feed
path 130 to the lift position 132 shown in FIG. 2. Here, the card
stack 136 is supported on a top side 192 of the stack support 124,
and the substrate 112, the pinch roller pairs 168A and 168B and the
top surface 184 of the card support member 180 are each positioned
on a bottom side 194 of the stack support 124, as shown in FIG. 2.
Thus, as used herein, the terms "top" and "bottom" refer to
relative positions along the axis 156, in which the top side or
position is located along the axis 156 in an upward direction,
which is indicated by arrow 196, from the bottom side or
position.
[0036] With the substrate 112 supported in the lift position 132
(FIG. 2), the lift mechanism 128 raises the card support member 180
using the drive mechanism 182 in the upward direction 196. In some
embodiments, the retraction mechanism 190 moves the upper transport
rollers 170 from their feed position, which is indicated in phantom
lines, away from the axis 156 as indicated by arrows 198. This
movement of the upper transport rollers 170 may also involve an
upward movement of the upper transport rollers 170 from their feed
positions along the axis 156. In some embodiments, this movement of
the upper transport rollers 170 by the retraction mechanism 190 is
driven in response to the upward movement of the card support
member 180 by the lift mechanism 128. Thus, in some embodiments,
the retraction mechanism 190 is driven by the drive mechanism 182
of the lift mechanism 128 using the motor 183.
[0037] Following this initial movement of the upper transport
rollers 170 from their feed positions, the upper transport rollers
170 reach a position in which they remain engaged with the card
substrate 112, such as the top surface 178 or the side edges of the
substrate 112, as shown in FIG. 5. As a result, the upper transport
rollers 170 continue to hold the substrate 112 in the lift position
132 relative to the axis 156 following this initial raising of the
substrate 112 toward the card stack 136.
[0038] As the lift mechanism 128 continues to raise the substrate
112 along the axis 156, the upper transport rollers 170 continue to
be moved further from the axis 156 from their position in FIG. 5
(shown in phantom lines) by the retraction mechanism 190 until they
are outside a projection of the substrate 112 along the axis 156,
as shown in FIG. 6. Further movement of the upper transport rollers
from their position in FIG. 6 (shown in phantom lines) allows the
lift mechanism 128 to continue to deliver the substrate 112 along
the axis 156 toward the opening 154 in the stack housing 140 to the
stack support 124 (e.g., catch pawls 158), as shown in FIG. 7.
Thus, the retraction mechanism 190 moves the upper transport
rollers 170 from their feed position (FIG. 2), in which the upper
transport rollers 170 engage the top surface 178 of the substrate
112, to a retracted position (FIG. 6), in which the upper transport
rollers 170 are displaced from the lifting path of the substrate
112 and are positioned below the substrate 112, in response to the
raising of the substrate 112 by the lift mechanism 128.
[0039] Next, the card support member 180 is driven by the drive
mechanism 182 to raise the substrate 112 along the axis 156 to the
top side 192 of the stack support 124 and in engagement with the
bottom of the stack 136, as shown in FIG. 8. For example, the drive
mechanism 182 delivers the substrate 112 through the catch pawls
158, which rotate in the direction 160 (FIG. 2), and in engagement
with the bottom substrate 112S of the stack 136. This positions the
substrate 112 on the top side 192 of the stack support 124.
[0040] The card support member 180 is then lowered along the axis
156 by the drive mechanism 182 to the lowered position, as shown in
FIG. 9. The catch pawls 158 rotate in the direction opposite the
arrows 160 (FIG. 2) to their support position, in which they
support the substrate 112 and the rest of the card stack 136.
Additionally, during the lowering of the card support member 180,
the retraction mechanism 190 pivots the upper transport rollers
170A and 170B of the pinch roller pairs 168A and 168B from their
retracted position (shown in phantom lines) to their feed position,
as indicated by the arrows in FIG. 9, to complete the card stacking
operation. Thus, the card feed mechanism 126 and the lift mechanism
128 are positioned to receive a new substrate 112' fed along the
card feed path 130, as indicated in FIG. 9.
[0041] The retraction mechanism 190 can take on any suitable form
while driving movement of the upper transport rollers 170 from
their feed position (FIG. 2) to their retracted position (e.g.,
FIG. 8). Exemplary embodiments of the retraction mechanism 190 will
be described with reference to FIGS. 10-14. FIG. 10 is an isometric
view of an exemplary base 144 of a card stacker 104, in accordance
with embodiments of the present disclosure. FIGS. 11-14 are side
cross-sectional views of the base 144 of FIG. 10 taken generally
along line 11-11, during various stages of a substrate lifting or
stacking operation. The upper transport roller 170A and the bottom
transport roller 172A are shown in phantom lines in order to show
features of the retraction mechanism 190.
[0042] In some embodiments, the retraction mechanism 190 includes
pivotable supports 200A and 200B, which are respectively attached
to the card support member 180 through suitable pivotable
connections 202A and 202B, such as hinges, for example. The
pivotable connections 202A and 202B allow the supports 200A and
200B to respectively pivot about axes 204A and 204B, which are
generally perpendicular to the direction the substrates 112 are fed
along the card feed path and the axis 156. The upper transport
roller 170A is connected to the support 200A and the upper roller
170B is connected to the support 200B. Thus, the transport rollers
170A and 170B move with movement of the corresponding support 200A
and 200B. In some embodiments, the transport rollers 170A and 170B
have a fixed position relative to the corresponding support 200A
and 200B.
[0043] The support 200A may be biased to pivot about the axis 204A
in the direction indicated by arrow 206A, and the support 200B may
be biased to pivot about the axis 204B in the direction indicated
by arrow 206B. In some embodiments, this biasing of the supports
200A and 200B is facilitated using conventional techniques, such as
a coil spring or another suitable biasing mechanism. The biasing of
the supports 200A and 200B about the corresponding axes 204A and
204B, also biases the upper transport rollers 170A and 170B in the
same manner. As a result, when the pinch rollers 168A and 168B are
in their feed position (FIGS. 2 and 11), the upper transport
rollers 170A and 170B are generally biased toward the top surface
178 of the card substrate 112 and pinch the card substrate 112
against the corresponding lower transport rollers 172A and 172B,
which engage the bottom surface 179 of the card substrate 112. In
some embodiments, the pinch roller pair 168A is configured to pinch
the card substrate 112 in the lift position 132 adjacent a first
edge 207 of the card substrate 112, and the pinch roller pair 168B
is configured to pinch the substrate 112 in the lift position 132
adjacent a second edge 208 of the substrate 112 that is opposite
the first edge 207, as best shown in FIG. 2.
[0044] As discussed above, in some embodiments, the movement of the
transport rollers 170A and 170B from the feed position to the
retracted position is driven in response to movement of the card
support member 180 from the lowered position (FIG. 2) to the raised
position (FIG. 8) during a substrate lifting or stacking operation.
In some embodiments, the movement of the card support member 180
from the lowered position to the raised position drives each of the
supports 200A and 200B to respectively pivot about the axes 204A
and 204B, and transitions the transport rollers 170A and 170B from
the feed position (FIG. 2) to the retracted position (FIG. 8). This
can be accomplished using any suitable technique.
[0045] In one exemplary embodiment, the transport rollers 170A and
170B are driven from the feed position to the retracted position
through engagement between the supports 200A and 200B and the
bottom transport rollers 172A and 172B. For example, the supports
200A and 200B may respectively include a slot 210A and 210B through
which shafts 212 of the corresponding bottom rollers 172A extend.
In some embodiments, the shafts 212 are supported by a frame 200 of
the base 144 and have a fixed position relative to the frame 200.
As a result, the card support member 180, the supports 200A and
200B, and the transport rollers 170A and 170B move relative to the
shafts 212 during movement of the card support member 180 along the
axis 156. Accordingly, as the card support member 180 moves along
the axis 156 during a substrate lifting or stacking operation, the
shafts 212 slide within the slots 210A and 210B relative to the
supports 200A and 200B. The slots 210A and 210B are shaped to pivot
the supports 200A and 200B and drive the transport rollers 170A and
170B from the feed position to the retracted position along a
desired path in response to the relative movement between the
shafts 212 and the supports 200A and 200B.
[0046] When the card support member 180 of the lift mechanism 128
is in its lowered position and the transport rollers 170A and 170B
are in their feed position, a card substrate 112 may be fed along
the card feed path 130 to the lift position 132, as shown in FIGS.
2 and 11. When in this position, the upper transport rollers 170A
and 170B are biased toward the top surface 178 of the substrate 112
and pinch the substrate 112 against the bottom rollers 172A and
172B. At the beginning of the lifting operation, the card support
member 180 engages the bottom surface 179 of the substrate 112 as
the card support member 180 is raised from its lowered position
along the axis 156, as shown in FIGS. 5 and 12. During this initial
movement of the card support member 180, the upper transport
rollers 170A and 170B are displaced from the corresponding bottom
rollers 172A and 172B and may be rotated slightly about the
corresponding axes 204A and 204B away from the central axis 156 in
response to the engagement between the shafts 212 and the
corresponding slots 210A and 210B, as shown in FIGS. 6 and 12.
[0047] As the card support member 180 continues to raise the
substrate along the axis 156 toward the raised position, the
supports 200A and 200B and the attached transport rollers 170A and
170B are driven to pivot about the corresponding axes 204A and 204B
in response to the engagement between the shafts 212 and the slots
210A and 210B in the direction indicated by arrows 214 in FIG. 12,
to the retracted positions shown in FIGS. 13 and 14. FIG. 13
illustrates the card support member 180 driving the substrate 112
through the opening 154 in the bottom of the stack housing 140, and
FIG. 14 illustrates the card support member 180 positioning the
substrate 112 in the fully raised position, in which the substrate
112 is positioned on the top side 192 of the stack support 124,
which is also shown in FIG. 8. The retracted positions (e.g., FIGS.
8 and 14) of the upper transport rollers 170A and 170B position the
rollers 170A and 170B on the bottom side 194 of the stack support
124 and outside of the lifting path of the substrate corresponding
to a projection of the substrate 112 along the axis 156.
[0048] The card support member 180 is then lowered along the axis
156 through the opening 154 in the housing 140 and back to its
lowered position shown in FIGS. 2 and 11 using the lift mechanism
128. This movement of the card support member 180 pivots the
supports 200A and 200B about the axes 204A and 204B and drives the
upper transport rollers from the retracted position (FIGS. 8 and
14) to the feed position (FIGS. 2 and 11), to prepare the base 144
for receiving another card substrate 112.
[0049] In some embodiments, the card stacker 104 includes a card
stack sensor 220 (FIGS. 1 and 2) that is configured to detect when
the stack housing reaches a full condition, such as illustrated by
card stacker 104B in FIG. 1, in which it no longer accepts
additional substrates in the card stack 136. In some embodiments,
the card stack sensor 220 is configured to detect a position of the
top substrate 112T in the stack 136 that indicates the full
condition. This may be accomplished using any suitable sensor
arrangement.
[0050] In some embodiments, the card stack sensor 220 includes a
passive or mechanical sensing element 222 in the stack housing 140
and an active or electronic sensor 224 in the base 144, as shown in
FIGS. 15 and 16, which are simplified partial side views of a card
stacker 104 in accordance with embodiments of the present
disclosure. This allows the card stacker 104 to provide the desired
full stack sensing feature without electrical connections between
the stack housing 140 and the base 144.
[0051] In some embodiment, the passive sensing element 222 includes
a mechanical switch 226 positioned at the top end 228 of the
interior cavity 146 of the stack housing 140. The active sensor 224
may be any suitable active sensor, such as an optical or capacitive
sensor, that is supported in the base 144 adjacent the receptacle
142 that receives the bottom 152 of the housing 140. Before the
stack 136 reaches a full condition, the top substrate 112T in the
stack 136 does not trigger the mechanical switch 226, as shown in
FIG. 15. However, as substrates 112 are added to the bottom of the
stack 136, the top substrate 112T rises relative to the mechanical
switch 226 and transitions the switch 226 from the first (not full)
position (FIG. 15), to a second position indicating a full
condition, as shown in FIG. 16.
[0052] The mechanical switch 226 may take on any suitable form. For
example, the mechanical switch 226 may comprise a lever arm 230
that is configured to pivot about an axis 232 from the first
position to the second position in response to the rising stack of
substrates 126. A rod 234 is attached to an end 236 of the lever
arm 230 and generally moves along the axis 156 in response to
movement of the lever arm 230 from the first position to the second
position. An end 238 of the rod 234 may initially be positioned for
detection by the active sensor 224 when the lever arm 230 is in the
first position, as shown in FIG. 15. When the lever arm 230
transitions to the second position, the end 238 of the rod 234 is
lowered and moved out of the detection zone of the active sensor
224. This lack of detection of the end 238 of the rod 234 by the
active sensor 224 may be used by the controller 108 to detect the
full condition of the substrate stack 136. Alternatively, the
mechanical switch 226 may be arranged to position the end 238
outside the detection zone of the active sensor 224 when the card
stack 136 has not reached the full condition, and position the end
238 within the detection zone of the active sensor 224 when the
card stack 136 has reached the full condition. Other card stack
sensing arrangements may also be used to provide the desired
detection of the full card stack condition within the stack housing
140.
[0053] In some embodiments, the active sensor 224 may also be used
to detect whether the stack housing 140 is properly installed on
the base 144. For instance, when the stack housing 140 is properly
installed on the base 144 and the card stack 136 is not full, the
lever arm 230 is in the first position and the end 238 of the rod
234 is positioned within the detection zone of the active sensor
224, as shown in FIG. 15. However, if the housing 140 is not
properly seated within the receptacle 142 of the base 144, the
active sensor 224 will not detect the end 238 of the rod 234. Thus,
the controller 108 can use the detection of the end 238 of the rod
234 by the active sensor 224 to determine that the stack housing
140 is properly installed within the receptacle 142 of the base
144.
[0054] Thus, the controller 108 may enable substrate lifting or
stacking operations to be performed by the card stacker 104, when
the active sensor 224 detects the end 238 of the rod 234, and
disable substrate lifting or stacking operations when the active
sensor 224 does not detect the end 238 of the rod 234, as this may
indicate that the stack housing 140 is either not installed on the
base 144, is improperly installed on the base 144, or the card
stack 136 has reached a full condition. However, the controller 108
may still use the base 144 to receive and pass substrates 112 to an
adjoining card stacker 104 when card lifting or stacking operations
are disabled. This is generally illustrated in FIG. 1, in which
card stacker 104B has reached a full condition, but is able to pass
a substrate 112 (shown in phantom lines) to the card stacker
104C.
[0055] In accordance with the above discussion, embodiments of the
present disclosure include a card stacker 104 that is configured to
deliver a card substrate 112 to a bottom of a stack 136 of card
substrates 112S. In some embodiments, the card stacker 104 includes
a stack support 124, a card feed mechanism 126, a card lift
mechanism 128, and a retraction mechanism 190, as shown in FIG. 2.
The stack support 124 is configured to hold the stack 136 of card
substrates 112 on a top side 192 of the stack support 124 that is
opposite a bottom side 194 of the stack support 124. The card lift
mechanism 128 is configured to support the card substrate 112 in a
lowered position (FIG. 2) on the bottom side 194 of the stack
support 124, and drive the card substrate 112 to a raised position
(FIG. 8), in which the card substrate 112 is positioned at the
bottom of the stack of card substrates 126 and is supported on the
top side 192 of the stack support 124.
[0056] Embodiments of the card feed mechanism 126 include an upper
transport roller 170A having a feed position (FIG. 2) when the card
substrate 112 is in the lowered position, and a retracted position
(FIG. 8) when the card substrate 112 is in the raised position. The
upper transport roller 170A engages a top surface 178 of the card
substrate 112 that faces the bottom side 194 of the stack support
124 when in the feed position (FIG. 2). The upper transport roller
170A is positioned on the bottom side 194 of the stack support 124
when in the retracted position (FIG. 8). The retraction mechanism
190 is configured to move the upper transport roller 170A between
the feed and retracted positions, as discussed above with reference
to FIGS. 4-9 and 11-14.
[0057] In some embodiments, the card lift mechanism 128 includes a
card support member 180 and a drive mechanism 182. The drive
mechanism 182 is driven by a motor 183 and drives the card support
member 180 between a lowered position (FIGS. 2 and 11)
corresponding to the lowered position of the card substrate 112,
and a raised position (FIGS. 8 and 14) corresponding to the raised
position of the card substrate 112.
[0058] In some embodiments, the retraction mechanism 190 includes a
first pivotable support 200A that is attached to the card support
member 180 and is configured to pivot the upper transport roller
170A about a support axis 204A to the retracted position in
response to movement of the card support member 180 from the
lowered position to the raised position, as discussed above with
reference to FIGS. 11-14.
[0059] In some embodiments, the card feed mechanism 126 includes a
lower transport roller 172A, and the card substrate 112 is pinched
between the transport rollers 170A and 172A when the card substrate
112 is in the lowered position, such as shown in FIGS. 2 and 11. In
some embodiments, the pivotable support 200A of the retraction
mechanism 190 is biased to pivot the upper transport roller 170A
about the first support axis 204A toward the top surface 178 of the
card substrate 112 when the card substrate 112. In some
embodiments, the transport rollers 170A and 172A form a first pinch
roller pair 168A that is configured to pinch the card substrate 112
in the lowered position adjacent a first edge 207 of the card
substrate 112.
[0060] In some embodiments, the card feed mechanism 126 includes a
second pinch roller pair 168B that includes upper and lower
transport rollers 170B and 172B, which pinch the card substrate 112
in the lowered position at a second edge 208 of the card substrate
112 that is opposite the first edge 207, as shown in FIG. 2.
[0061] In some embodiments, the upper transport roller 170B
includes a feed position when the card substrate 112 is in the
lowered position, as shown in FIGS. 2 and 11, and a retracted
position when the card substrate is in the raised position, as
shown in FIGS. 8 and 14. The upper transport roller 170B engages
the top surface 178 of the card substrate 112 when in the feed
position, and the upper transport roller 170B is on the bottom side
of the stack support 124 when in the retracted position, as shown
in FIGS. 2 and 8.
[0062] The retraction mechanism 190 is configured to move the upper
transport roller 170B between the feed and retracted positions, as
discussed above with reference to FIGS. 2-9 and 11-14. In some
embodiments, the retraction mechanism 190 includes a second
pivotable support 200B that is attached to the card support member
180 and is configured to pivot the upper transport roller 170B
about a second support axis 204B to the retracted position in
response to movement of the card support member 180 from the
lowered position to the raised position.
[0063] Additional embodiments are directed to a method of
performing a substrate stacking operation using the card stacker
104 formed in accordance with one or more embodiments described
herein. In one embodiment of the method, a card substrate 112 is
received using a card feed mechanism 126 of the card stacker 104
that includes a transport roller 170, such as shown in FIGS. 1 and
2. The card substrate 112 is supported in a lift position (FIG. 2)
in a card path 130 on a bottom side 194 of the stack support 124.
In some embodiments, a top surface 178 of the card substrate 112
that faces the bottom side 194 of the stack support 124 is engaged
with the upper transport roller 170 (e.g., roller 170A), in a feed
position, as shown in FIG. 2. The card substrate 112 is then raised
from the lift position to a raised position, in which the card
substrate 112 is positioned on the bottom of the stack of card
substrates 136 and supported on the top side 192 of the stack
support 124 using a card lift mechanism 124, as discussed above
with reference to FIGS. 2-8 and 11-14. During the lifting or
stacking operation, the transport roller 170 is moved from the feed
position to a retracted position, in which the transport roller is
positioned on the bottom side 194 of the stack support 124.
[0064] It is appreciated that certain features of the present
disclosure, which are, for clarity, described in the context of
separate embodiments, may also be provided in combination in a
single embodiment. Conversely, various features of the present
disclosure, which are, for brevity, described in the context of a
single embodiment, may also be provided separately or in any
suitable subcombination or as suitable in any other described
embodiment of the present disclosure. Certain features described in
the context of various embodiments are not to be considered
essential features of those embodiments, unless the embodiment is
inoperative without those elements.
[0065] Although the embodiments of the present disclosure have been
described with reference to preferred embodiments, workers skilled
in the art will recognize that changes may be made in form and
detail without departing from the spirit and scope of the present
disclosure.
* * * * *